Documente Academic
Documente Profesional
Documente Cultură
03-3
1. SPECIFICATION
Description
Specification
Fuel
Diesel
Type
Filter type
Fuel filter
Change interval
Injector
Fuel tank
EU
every 40,000 km
GEN
every 45,000 km
200 cc
Heater capacity
250W 13.5V
System pressure
1800 bar
Type
Operating type
-40 ~ 125
Operating pressure
1800 bar
Operating temperature
-30 ~ 120
Type
Vane type
0.5 : 1
Pressure
6 bar
Capacity
57 L
Material
Plastic
Fuel sender
03-4
2. MAJOR CHANGES
Filter
Part SGN NO.
0000-00
03-5
Follow the below procedures before starting service works for fuel system.
4. If the problem is from HP pump, fuel supply line or injector, prepare the clean special tools and sealing
caps to perform the diagnosis for DI engine fuel system in this manual. At this point, thoroughly clean
the related area in engine compartment.
03-6
5. Follow the job procedures. If you find a defective component, replace it with new one.
Once disconnected, the fuel pipes between HP pump and fuel rail and between fuel rail and each
injector should be replaced with new ones. The pipes should be tightened tospecified tightening torques
during installation. Over or under torques out of specified range may cause damages and leaks at
connections. Once installed, the pipes have been deformed according to the force during installation,
therefore they are not reusable. The copper washer on injector should be replaced with new one. The
injector holder bolt should be tightened to specified tightening torque as well. If not, the injection point
may be deviated from correct position, and it may cause engine disorder.
6. Plug the removed components with clean and undamaged sealing caps and store it into the box to
keep the conditions when it was installed.
Fuel filter assembly
Priming pump
0000-00
03-7
8. Check the installed components again and connect the negative battery cable. Start the engine and
check the operating status.
9. With Scan Tool, check if there are current faults and erase the history faults.
03-8
0000-00
03-9
03-10
Example:
-
0000-00
(2) Pre-inspection
-
03-11
03-12
If several DTCs are output simultaneously, check the electric wiring for open or short circuit.
Check the low pressure fuel system and fuel filter and confirm that there are no abnormalities. Carry
out the high pressure fuel system check.
0000-00
03-13
03-14
0000-00
03-15
The fuel rail pressure value can be checked using a diagnostic device.
03-16
3. Disconnect the key connector for fuel filter connection, and connect both connectors to the fuel filter
and hose.
4. Start the engine and check visually for clogged low pressure fuel system, excessive air or air entry.
If the fuel flow is not sufficient or air is in the fuel, repair the leak area.
5.
0000-00
03-17
below 20 cm
03-18
Dynamic test for backleak of injector
1. Warm up the engine so that the engine
coolant temperature be over 80 and star
2. the engine again.
Disconnect the injector return hose and cover
the openings with caps shaped screw
(included in the special tool).
38 ml or less
0000-00
03-19
The pressure leak test procedure is performed in 4 cycles. The engine speed goes up to
3,500 rpm and down again four times for 18 seconds. If the system is OK, the "System OK"
message will be displayed.
03-20
HP pump pressure test
1. Prepare a special tool for high pressure test
and clean it thoroughly to prevent foreign
materials from entering.
0000-00
03-21
1. DI Engine
Comparatively conventional diesel engines, DI engine controls the fuel injection and timing electrically,
delivers high power and reduces less emission.
2. System Safety Mode
When a severe failure has been occurred in a vehicle, the system safety mode is activated to protect the
system. It reduces the driving force, restricts the engine speed (rpm) and stops engine operation. Refer
to "Diagnosis" section in this manual.
3. Engine CHECK Warning Lamp
The Engine CHECK warning lamp on the instrument cluster comes on when the fuel or
major electronic systems of the engine are not working properly. As a result, the
engines power output may decrease or the engine may stall.
03-22
2) Cleanness
(1) Cleanness of DI engine fuel system
Cleanness of DI engine fuel system and service procedures
The fuel system for DI engine consists of transfer (low pressure) line and high pressure line.
Its highest pressure reaches over 1,600 bar.
Some components in injector and HP pump are machined at the micrometer 100 m of
preciseness.
The pressure regulation and injector operation are done by electric source from engine ECU.
Accordingly, if the internal valve is stuck due to foreign materials, injector remains open.
Even in this case, the HP pump still operates to supply high pressurized fuel. This increases the
pressure to combustion chamber (over 250 bar) and may cause fatal damage to engine.
You can compare the thickness of injector nozzle hole and hair as shown in below figure (left side). The
below figure shows the clearance between internal operating elements.
Hair
Operating
clearance
0.002 mm
Diameter
0.04 mm
Diameter
2.0 mm
Nozzle hole
The core elements of fuel system has very high preciseness that is easily affected by dust or very small
foreign material. Therefore, make sure to keep the preliminary works and job procedures in next pages.
If not, lots of system problems and claims may arise.
0000-00
03-23
(2) Di engine and its expected problems and remedies can be caused by
water in fuel
System supplement against paraffin separation
In case of Diesel fuel, paraffin, one of the elements, can be separated from fuel during winter and then
can stick on the fuel filter blocking fuel flow and causing difficult starting finally. Oil companies supply
summer fuel and winter fuel by differentiating mixing ratio of kerosene and other elements by region and
season. However, above phenomenon can be happened if stations have poor facilities or sell improper
fuel for the season. In case of DI engine, purity of fuel is very important factor to keep internal
preciseness of HP pump and injector.
Accordingly, more dense mesh than conventional fuel filter is used. To prevent fuel filter internal clogging
due to paraffin separation, SYMC is using fuel line that high pressure and temperature fuel injected by
injector returns through fuel filter to have an effect of built-in heater (see fuel system).
Water separator
03-24
1. OVERVIEW
The components in the fuel system supply fuel and generate high pressure to inject fuel to each injector.
They are controlled by the engine ECU.
The common rail fuel injection system consists of fuel tank, fuel line, low pressure line which supplies low
pressure fuel to the low pressure pump (includes high pressure pump), high pressure line which
connected to the injector and the engine control unit (ECU) which calculates the accelerator pedal
position and controls the overall performance of vehicle based on the input signals from various sensors.
Fuel filter
(Priming pump)
Low pressure line
HP fuel pump
Common rail and
Injector
Fuel neck
ENGINE CONTROL
SYSTEM
Engine ECU (D20DTF)
03-26
0000-00
Accelerator pedal
position sensor
03-27
T-MAP sensor
HFM
03-28
The fuel from the fuel tank is supplied to the fuel heater of fuel filter/priming pump and then low pressure
generated by the low pressure pump (built into HP pump) is transmitted to the HP pump.
The fuel pressure at the HP pump is controlled by the IMV valve, and the maximum allowed pressure is
1,800 bar. The compressed fuel at the fuel pump is delivered to the rail, and injected by the injectors
according to the injection signals. The injection method is the same with the conventional method; Fuel
return by backleak which operates the needle valve.
The major difference is that the fuel return line is connected to the fuel filter inlet port, not the HP pump
venturi.
The pressure from the high pressure pump is increased to 1,800 bar from 1,600 bar, and the pump is now
installed to the cylinder head (cylinder block for previous model). The fuel pressure is generated by the
operation of intake camshaft and gears. The specifications for the IMV valve and the fuel temperature
sensor are not changed.
0000-00
3) Input/Output devices
03-29
03-30
The engine ECU calculates the accelerator pedal based on the input signals from various sensors, and
controls the overall operation of the vehicle.
The ECU receives the signals from various sensor through data line, and performs effective air-fuel ratio
control based on these signals.
The crankshaft speed (position) sensor measures the engine speed, and the camshaft speed (position)
sensor determines the order of injections, and the ECU detects the amount of the accelerator pedal
depressed (driver's will) by receiving the electrical signals from the accelerator pedal sensor.
The mass air flow sensor detects the volume of intake air and sends the value to the ECU.
The major function of the ECU is controlling air-fuel ratio to reduce the emission level (EGR valve control)
by detecting instantaneous air flow change with the signals from the mass air flow sensor.
Also, the ECU uses the signals from the coolant temperature & air temperature sensors, booster pressure
sensor, atmospheric pressure sensor to: a) determine injection starting point and set value for pilot
injection, and b) deal with various operations and variable conditions.
0000-00
03-31
03-32
5) Circuit Diagram